US8923478B2 - X-ray inspection apparatus for pipeline girth weld inspection - Google Patents

X-ray inspection apparatus for pipeline girth weld inspection Download PDF

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Publication number
US8923478B2
US8923478B2 US13/501,874 US201013501874A US8923478B2 US 8923478 B2 US8923478 B2 US 8923478B2 US 201013501874 A US201013501874 A US 201013501874A US 8923478 B2 US8923478 B2 US 8923478B2
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ray
ray source
pipeline
inspection apparatus
directional
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US20120201348A1 (en
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Stephen Knight
Stephen G. Drake
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Sps Acquisition LLC
SHAW INSPECTION SYSTEMS Ltd
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Shawcor Ltd
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Assigned to SHAW INSPECTION SYSTEMS LIMITED reassignment SHAW INSPECTION SYSTEMS LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KNIGHT, STEPHEN, DRAKE, STEPHEN G.
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
    • G01N23/02—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material
    • G01N23/06—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and measuring the absorption
    • G01N23/18—Investigating the presence of flaws defects or foreign matter
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
    • G01N23/02—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material
    • G01N23/06—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and measuring the absorption
    • G01N23/083—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and measuring the absorption the radiation being X-rays
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2223/00—Investigating materials by wave or particle radiation
    • G01N2223/60—Specific applications or type of materials
    • G01N2223/628—Specific applications or type of materials tubes, pipes

Definitions

  • This invention relates to an x-ray inspection apparatus and method for pipeline girth weld inspection.
  • pipeline girth (circumferential) welds are often inspected with radiography using a conventional x-ray crawler in conjunction with either x-ray film or real-time radiographic (RTR) detectors.
  • RTR real-time radiographic
  • crawlers are used when access can be easily made to an open end of a pipeline section which is being welded to another pipeline section.
  • the x-ray crawler comprises an x-ray source on a crawler or buggy which can be driven into the open end of the pipeline and which will crawl along the pipeline to the area of the circumferential weld.
  • the x-ray source is panoramic and mounted to be substantially central within the pipe and emits x-rays around a 360 degree arc around the weld surface.
  • This type of x-ray source is generally used with x-ray film and is suitable for most pipe diameters.
  • x-ray film requires time consuming and environmentally unfriendly chemical processing, washing and drying prior to the production of an image which can be viewed and stored.
  • RTR detectors may be used with a pipe center mounted panoramic x-ray source.
  • their applications are typically limited to pipe diameters of 24 inches or less, as inspection times on larger diameters increase rapidly. This arises because as the pipe diameter increases, the intensity of x-ray flux at the weld falls off in accordance with the inverse square law as distance from the x-ray source increases. The result of this is that on medium to large diameter pipes, the x-ray flux is of such a reduced level that inspection with RTR detectors is unacceptably slow and therefore not commercially viable.
  • Preferred embodiments of the present invention provide a directional x-ray source, means for inserting the directional x-ray source into a pipeline section and for rotating the directional x-ray source through 360 degrees substantially coaxially with the pipeline section, whereby the directional x-ray source directs x-rays at the pipeline girth weld from a substantially constant distance around the weld, and an RTR detector system positioned externally of the pipeline weld.
  • the x-ray intensity levels at the RTR detection system are increased significantly compared to a conventionally deployed panoramic x-ray source (e.g. by ten times on a 48 inch diameter pipe) and the effects of the inverse square or flux reduction with increased pipe diameter are eliminated.
  • the scanning speed of the RTR detector at a constant wall thickness is related only to the pipeline circumference. This enables large diameter pipe circumferential welds to be rapidly inspected with a single RTR detector which scans around a weld in synchronism with an x-ray source on a suitable x-ray crawler.
  • FIG. 1 shows a cross-section view through a pipeline in which an apparatus embodying the present invention is positioned with an x-ray detection system mounted externally to the pipeline.
  • FIG. 2 shows a perspective view of the same pipeline.
  • FIG. 3 shows an end view into the pipeline with the crawler head in different positions.
  • FIG. 4 shows the invention in a pipe mill or pipe yard where two or three lengths of pipe are often jointed together prior to transport to the pipeline under construction.
  • the apparatus comprises a conventional crawler chassis 1 as shown in FIGS. 1 and 2 of the type used in prior art systems.
  • This consists of a main chassis body, motor/gearbox drives 22 and drive wheels 20 at the front and back, and a battery box 24 for powering the x-ray source and the motors.
  • the crawler is controlled by an electrical control panel that contains the x-ray controller, programmable logic controller (PLC), motor drives and interfaces.
  • PLC programmable logic controller
  • the chassis front differs from conventional designs in that it includes a strong mounting point for an offset rotate mechanism.
  • This mechanism comprises a rotate gear motor 2 supported in a strong frame 3 securely fixed to the crawler chassis.
  • the gear motor shaft is fixed to a rotatable member or disk 4 .
  • the rotatable member 4 has an offset mounted support cradle 30 for carrying an x-ray source 5 .
  • This support cradle also carries an inclinometer 6 and a gamma ray detector 7 .
  • a height adjustment device built into the frame 3 enables the position of the rotatable member relative to the axis of rotation of the motor 2 , about which it is turned, to be moved, thereby moving the support cradle 30 radially inwards and outwards in the pipe to enable the position of the x-ray source in relation to the inside pipe wall to be adjusted for different pipe diameters and different inner pipe wall stand-offs required to achieve desired radiographic performance criteria.
  • the proposed inspection cycle is as follows: —
  • the x-ray crawler is signalled to traverse forward along the inside of a pipe by a conventional gamma signalling device 9 , operated external to the pipe or by other means such as, but not limited to, radio, magnetic or ultrasound.
  • an inclinometer 6 constantly adjusts the x-ray tube radial orientation such that its beam output window is always orientated in the same direction. By example this could be towards the top of pipe position. This technique also ensures that the gamma ray detector 7 is in a suitable position such as to be able to detect the external gamma signalling device 9 .
  • FIG. 1 shows the gamma signalling device 9 at the top of the pipe.
  • the gamma ray detector 7 identifies the peak signals from two individual and separated detection devices placed inside the gamma ray detector 7 at the housing front and rear.
  • a programmable logic controller uses these signals to slowly position the crawler correctly by moving the drive wheels in both forward and reverse directions to position both gamma ray detectors directly under the beam emitted from the external gamma signalling device 9 . This position is attained when the signals at each detection device are the same.
  • the gamma signalling device 9 position places the directional x-ray beam center in such a position as to penetrate the pipe wall at the center of the weld, when the gamma ray detectors are so positioned. This arises because the gamma rays pass through the pipeline material, which should be substantially consistent in the transmission of gamma rays. Therefore, the intensity of the rays will slope off evenly in each side of the device 9 , and the lateral displacement of the gamma signalling device in relation to the x-ray source and detector is substantially the same as its displacement in relation to the weld to be inspected.
  • the operator removes the gamma signalling device from the pipe, and triggers an x-ray generation sequence.
  • the operator moves away from the pipe to a safe distance.
  • the directional x-ray source 5 emits x-rays at a pre-set voltage, current and time direction after a pre-warning safety period.
  • the RTR Detection System 10 which, for example, is mounted on a steel band 11 and driven around the pipe by a rack/pinion system 12 .
  • the RTR Detection System 10 On detection of the x-ray flux, the RTR Detection System 10 enters a ‘beam centre search mode’ to position the detector directly into the position of maximum x-ray flux by moving in both clockwise and counter clockwise directions around the pipe circumference and sampling the strength of the x-rays detected. Once the beam edge positions have been detected where the detected x-ray flux goes beneath a threshold level, the detector moves to a rotational position substantially midway between these points. Because of the high x-ray flux provided by the directional x-ray source, this operation only takes a few seconds to complete.
  • both the x-ray source 5 and the real-time x-ray detector 10 then start to rotate at a pre-determined fixed rotational speed together around the pipe.
  • the detector samples the detected x-rays at a plurality of sampling points around the weld. This is a design variable and is dependent on the x-ray source, the RTR device and the pipeline diameter.
  • FIG. 3 a), b), c) and d) show the crawler with the x-ray source in different rotational positions.
  • the sampled data from the RTR detection may overlap and can therefore be accumulated to reduce the effects of noise. Alternatively they may not overlap. Whichever is selected, the end result is a linear profile of the penetration of x-ray flux through the weld with positions around the weld.
  • the combination of the inclinometer 6 for x-ray tube rotational positioning, the gamma ray detection 7 & 8 methodology and the RTR detector beam search mode ensures that both the x-ray source and RTR detector are accurately aligned to start the orbit of the pipe weld in synchronism.
  • X-rays then automatically switch off when the pre-set exposure time has been reached.
  • the operator then signals the crawler 1 using the gamma signalling device 9 to move to the next pipe weld using the gamma signalling device.
  • the RTR detector and drive mechanism may be removed from the pipe.
  • the inspection process is repeated on the next and further welds as required.
  • the speed of rotation is proportional to pipeline diameter.
  • the x-ray detector may be based on a highly customised version of an existing product used in dentistry and designed specifically for low dose, high speed panoramic x-ray.
  • This commercial product scans a patient's jaw at high speed using a multiple line charge coupled device (CCD) which can either directly or indirectly convert low energy x-rays to an electronic signal.
  • CCD multiple line charge coupled device
  • one commercially available system is made up of a 3072 ⁇ 128 element CCD covering 150 mm width.
  • the scan speed of the mechanism that orbits the patient's jaw is linked to the charge transfer rate from line to line on the CCD, resulting in a single output signal row with 128 times the amplitude of a single row of detectors.
  • This type of detector is commonly called a ‘time division integration’ device.
  • the CCD moves around its scanning arc in a direction perpendicular to its 128 rows of CCD elements.
  • Each element is, for example 50 microns in diameter.
  • Charge from the elements in each row is read in a first scan and stored in respective ones of a plurality of registers, one register for each row, and each register including a storage element for each CCD element.
  • the CCD then advances and a second scan is performed when it has advanced a distance substantially equal to one row of CCD elements (in this case 50 microns). Charge from the elements in each row is read in the second scan. The charge is added to charge already stored for the respective row position in relation to the article being scanned. That is to say, on the first scan the leading row of CCD elements will have its charge stored in a first register, the second row in a second register, and so on. On the second scan, the leading row of CCD elements will have its charge stored in a new register. The second row of CCD elements will have its charge added to the charge in the first register as it is now detecting in the same position as the first register was on the first scan.
  • one row of CCD elements in this case 50 microns.
  • This process of stepping through registers and adding charge to each one each time the CCD elements have moved by one row for a further scan continues until charge from the final row of CCD elements has been written to the first register.
  • data from the first register can be sent to a digitizer and serial communication converter.
  • the register corresponding to the second position of the first row of the CCD elements will be finished accumulating charge and can be sent to the digitizer. This process continues for the whole of the item being scanned. Thus, for each position on the scan, the charge from 128 rows of CCD elements is accumulated into a single register, for each position on the scan, thereby producing a signal where only significant variations will be masked by noise.
  • the overall system used by the detector described in this embodiment uses the same principles as the commercial dental product described above, but has been adapted for use with weld inspection.
  • other detection systems may be used with embodiments of the invention as will be apparent to those skilled in the art.
  • the proposed system has two further novel features to increase radiation safety and reduce the required personnel exclusion barrier distances.
  • the x-ray source 5 emitted beam is a highly collimated ‘fan’ beam 32 to cover the RTR detector input window with only a small overlap.
  • a radiation absorbing shield 14 is attached to the RTR detector window to attenuate the entire primary beam from the x-ray source 5 such that the only x-rays present at the pipe outer surface are lower level scattered radiation.
  • FIG. 4 shows another application of the invention in pipe mills that join two or three pipes together, often referred to ‘double jointing’ and ‘triple jointing’ respectfully.
  • the radiographic inspection of these girth welds could be carried out by using the invention in full or by mounting the rotating section of the invention, or a similar configuration onto a boom arm or other load supporting device as shown in FIG. 4 .
  • This boom or arm 35 carrying the rotating sections could then be inserted into the pipeline, correctly positioned for rotation of the x-ray source a fixed distance from the inner pipeline surface using, for example, a support ‘spider’ 33 and supporting wheels 34 , and a similar x-ray detector system positioned externally.
  • the boom arm or other load supporting device can be positioned manually or by using a motorised system.

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  • Health & Medical Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
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  • Analysing Materials By The Use Of Radiation (AREA)
US13/501,874 2009-10-13 2010-10-12 X-ray inspection apparatus for pipeline girth weld inspection Active 2031-08-23 US8923478B2 (en)

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GBGB0917950.8A GB0917950D0 (en) 2009-10-13 2009-10-13 X-ray inspection method and apparatus for pipeline girth weld inspection
GB0917950.8 2009-10-13
PCT/GB2010/001900 WO2011045563A1 (en) 2009-10-13 2010-10-12 X-ray inspection apparatus for pipeline girth weld inspection

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EP (1) EP2488856B1 (es)
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CA (1) CA2776000C (es)
DK (1) DK2488856T3 (es)
ES (1) ES2472941T3 (es)
GB (1) GB0917950D0 (es)
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RU (1) RU2533760C2 (es)
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CA2776000A1 (en) 2011-04-21

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